Felted waterproof composition and process of making same



Patented Aug. 20, 1929.

, UNITED STATES LESTER KIRSCHBRAUN,

OF CHICAGO, ILLINOIS.

FELTED WATERPROOF COMPOSITION AND PROCESS OF MAKING SAME.

No Drawing.

This invention relates to improvements in felted waterproof compositions and process of making same, and has among its salient objects to provide a process which is particularly adapted to be carried on in a multicylinder paper forming machine in which the sheet is formed of a plurality of relatively thin felted plies; to provide a process in which the multiplicity of plies are adhesively bound together in the formation of the paper so as to produce a substantially unitary structure; to provide a process which permits the use of fibre stock of different character in the different plies and also the use of variable character of bituminous or analogous binders in the different plies; to provide a process in which the percentage or amount of binder in the various plies can be varied or eliminated entirely out of any one or more plies; to provide a process which will permit the use of relatively cheap fibre stocks which cannot ordinarily be saturated with asphalt or the like by heretofore known methods; to provide a process in which any one or more of the plies may have different color than the other, which can be accomplished either in the binder or fibre or both; to provide a process which can be utilized on a standard multic linder paper machine without any substantlal modification of such machine; to provide a novel product of the above character.

In my previously filed application, Serial No. 339,690, filed Nov. 21, 1919, issued as patent No. 1,615,303, I have described in detail the method of converting an adhesive binder such as asphalt into non-adhesive condition, as for example, a non-adhesive emulsion. I have also there described the mixing of said emulsion with paper stock, and the sheeting of such mixture on a paper forming machine. I have also there described the manner in which the extremely finely dispersed particles of asphalt are uniformly distributed throughout the fibres and upon application of heat coalesce to produce a substantially continuous asphaltie film surrounding the fibres. In other words, the particles of asphalt are no longer in discrete form but have united with each other to form a continuous saturating medium distributed throughout the sheet.

In this application, as in the one heretofore filed and above referred to, I first make a non-adhesive emulsified matrix of asphalt or other analagous binder) water and a colloid,

screenings, cotton linters, rope waste.

Applieationfiled May 24, 1920, Serial No. 383,893. Renewed fiovember 7, 1925.

as for example clay, in which the asphalt forms the internal phase. In this emulsion,

stock and asphalt (either or both) may be varied for each ply. For example, the center ply may have a. low melting point asphalt as Mexican oil steam distilled asphalt of 105 F. melting point and 175 to 200 penetration. This will give a flexible ply. The

fibre may be either rag stock or old newspapers. In the next two or intermediate plles, 1. e., those next to the center ply, the asphalt may be an oxidized or air blown asphalt made from the petroleum residuum, of

mid-continental oil as for example, Illinois crude. This asphalt may have .a melting point of 150 F. and a penetration of 100.

The fibre may be bagging or sulphate pulp or mixtures thereof. Sawdust also may be added to any of the three inner plies, in order to open up the sheet.

The emulsion for the two outer plies may be made of a relatively hard asphalt, for example, asphaltic compound composed of Gilsonite and asphalt residuum brought to a penetration of ten to fifteen and a melting point. of 160 to 175 F. up to as high'as 250 F. In these plies fibre may be sulphilte T e fibres may be colored by dyes, as for example, red, yellow or any color.

- If desired, the pitch may be colored and in such case might be the residue from superheated steam distillation of wax tailings from petroleum oil suitably colored with an oil soluble dye. Also a compound such as Gilsonite fluxed with stearine, pitch may be used to which is added a pigment- Either the binder or the fibre or both may be colored.

In any of the plies, the percentages of the asphalt or hinder relative to the fibre may be varied. For complete saturation, it normally takes for each ply 55% to 60% by weight of asphalt, 8% to 12% of clay and the remainder fibre. Also in the outer plies the amount of asphalt may be entirely eliminated.

It is to be understood that the sheet'is formed and dried in the inulti-cylinder paper machine by passing over cylindrical driers in the usual way. A sheet formed in this way may be used for a wide variety of purposes. By the term bitumen or pitch, as used in the claims, I intend to include these waterproofing substances hereinbefore described.

I claim as my invention:

1. A wate'rproof feltedcomposition consisting of a plurality of felted plies, the fibre of one ply being of different character than the fibre of another ply and a continuous coalesced bituminous film containing an emulsifying agent extending through each ply said plies having the characteristics of eing. simultaneously felted together during the forming operation.

2. A waterproof felted composition consisting of a plurality of felted plies, the fibre of one ply being of different character than the fibre of anothereply and a continuous coalesced bituminous film extendingthrough each ply, and clay incorporated with the bitumen.

3. A waterproof felted composition consisting of a plurality of plies, each containing fibre and a continuous coalesced bituminous film, the bituminous medium in one ply being of a different character than the bituminous medium of another ply.

4. A waterproof felted composition consisting of a plurality of. felted fibrous plies, and a bituminous coalesced film extending through each ply, the film in one ply having a higher melting point than'the film in another p A waterproof felted composition consisting of a plurality of felted fibrous plies, and a bituminous coalesced film extending through each ply, the film in one ply having allower penetration than the film in another p y- 6. A process of -making a. waterproof felted composition consisting in passing a mixture of fibre and a non-adhesive emulsified matrix containing water, bitumen and colloidal clay over a multi-cylinder paper forming machine, sheeting and drying the stock to coalesce the bitumen and form a continuous waterproofing film, the emulsified matrix for one ply having a bitumen of different character than the emulsified matrix of another ply. q

7 A process of making a waterproof felted composition consisting in passing a mixture of fibre and a non-adhesive emulsified matrixcontaining water bitumen and colloidal clay over a multi-cylinder paper forming machine, sheeting and drying the stock to coalesce the bitumen and form a continuous waterproofing film, the fibres of one ply being of different character than the fibres of the other plies.

8. A waterproof felted com osition, con-' sisting of a plurality of felte fibrous plies and a bituminous substance dispersed with an emulsifying agent extending through each ply in the form of coalesced continuous film, said plies having the structure characteristics of simultaneous formation.

9. A waterproof felted composition, consisting of a plurality of felted fibrous plies and a bituminous substance with an emulsify-- ing agent in the form of a continuous coalesced film extending through each ply, the coalesced substance in'oneply having a higher melting point than the substance in another ply.

10. A Waterproof felted composition consisting of a plurality of felted fibrous plies and a bituminous substance with an emulsifying agent in the form of a continuous coalesced film extending through eachply, the coalesced substance in one ply having a lower penetration than the substance in another Xly 11. process of making a waterproof multi-ply sheet consisting in forming a plurality of fibrous plies upon a multi-cylinder machine, the stock of a plurality of said plies having mixed therewith a normally adhesive bitumen in non-adhesive emulsifiedform, removing the water from the sheet and causing the bitumen to coalesce as a continuous film coating the fibres.

12. A waterproof sheet comprising a plu-.

rality of fibrous plies, several of said plies having coalesced therethrough a continuous fused waterproof pitchy medium, the plied product having the structural characteristics of simultaneous formation.

13. A process of making a waterproof multi-ply sheet comprising forming a plurality of fibrous plies into a sheet, mixing with the stock of a plurality of said plies before the plies are united a normally adhesive bitumen in non-adhesive emulsified form, removing the water from the sheet and causing the bitumen to coalesce.

14. A process of making a waterproof felted composition, comprising forming a plurality of fibrous plies into a sheet, the stock of each ply having mixed therewith a normally adhesive bitumen in non-adhesive emulsified form, removing the water from the sheet and causing the bitumen to coalesce.

15. A multi-ply sheet comprising a lurality of plies o'f fibrous stock, each ly aving coalesced therethrough a 'fuse waterproof substance in the form of a continuous coalesced film enveloping the fibres and derived from an 'emulsionof said waterproofing substance and an emulsifying agent and possessing the characteristics of having had the waterproofing material incor orated simultaneously with the formation t ereof.

r16. A multi-ply waterproof sheet comprising a Iplurality of fibrous plies, several'of said plies aving coalesced therethrou'gh a,(30l1t111- uous fused waterproofing medium, the fibres andwaterproofing medium contained in one of the plies being interlocked and integrated with the adjacent ply whereby to prevent separation thereof.

17 A multi-ply waterproofed sheet comprising a plurality of fibrous plies, several of said plies having coalesced therethrough a ing interlocked and integrated with the -ad-' jacent ply whereby to prevent separation thereof.

LESTER KIRSCI-IBRAUN- 

